1

COURSE NAME : DIPLOMA IN MECHANICAL ENGINEERING

COURSE CODE : ME /PT/PG
SEMESTER : FIFTH
SUBJECT TITLE : METROLOGY AND QUALITY CONTROL
SUBJECT CODE :
Teaching and Examination Scheme:

Teaching Scheme Examination Scheme
TH TU PR
PAPER
HRS
TH PR OR TW TOTAL
03 -- 02 03 100 25# -- 25@ 150
# External Assessment, @ Internal assessment, TH-Theory, PR- Practical, TW-Term Work
NOTE: Two tests each of 25 marks to be conducted as per the schedule given by
MSBTE. Total of tests marks for all theory subjects are to be converted out of 50
and to be entered in mark sheet under the head Sessional Work. (SW)
Rationale:
The Diploma mechanical Engineer should understand, select and use various
measuring instruments as he often comes across measuring different parameters of
machined components and the appropriate fitment of interchangeable components in the
assemblies.
The knowledge of the subject also forms the basis for the design of mechanical
measurement systems, design & drawing of mechanical components.

Objectives:
Students will be able to:
1. Understand and calculate the least count of all basic measuring instruments.
2. Select and use appropriate instrument/s for specific measurement.
3. Understand the systems of limits, fits and tolerances and correlate with machine
drawing and manufacturing processes.
4. Analyze and interpret the data obtained from the different measurements
processes and present it in the graphical form, statistical form for understanding
the concepts of SQC.
5. Construct, draw and interpret the control charts.
2

Measurement of different parameters
of machined components, Use &
handling of different measuring
instruments , Procedure of
comparing instrument with
standards. Selection of appropriate
instruments on criterion for specific
measurement.
ISO certification procedure,
Frequency distribution,
Control chart plotting, Process
capability determination,
Sampling inspection
procedure, Economics of
quality
Principle of least count, limits fits and
tolerances, Gauge design, optical
Interferometry, Principle of Surface
quality, Principle of Linear/Angular
Measurement, terminology of
threads/Gear and measurement of
their elements.

Statistical Analysis,
Quality Assurance,
Quality Maintenance
Precision, Accuracy, Repeatability,
Sensitivity, Standards of
Measurement, Calibration &
Traceability, Reliability, error
analysis

Cost of quality, Value of Quality,
Quality characteristics,
Measurement of quality,
Controlling quality, Vendor
Rating, Histograms, Basic
statistics, Frequency Normal
Distribution curve, Control charts,
Steel Rule, Vernier Scale
instruments, Micrometers, Slip
gauges, Angle gauges, Sine bar, Go-
No-Go gauges, Comparators, optical
measuring instruments, Geometrical
Parameter testing instruments..
Machined components,
Industrial data, Production
machines with capability of
producing components in
different accuracy zones.
Procedures
Principles
Concepts
Facts

Learning Structure:


To select & use different measuring instruments to measure the
Application qualitative & quantitative characteristics of different machined
components. Statistically analyze the data. Decide action to be
taken for controlling the quality. Understand ISO quality standard
system







.


























3

Theory
Topic & Content Hours Marks
1.Introduction to metrology --------------------------------18 Marks
Specific Objectives
To understand the basics of Metrology & calculate the least count of
measuring instruments.
To understand various standards, comparators, gauge selection and
limit system.
1.1Metrology Basics ---------------------06Marks
Definition of metrology, objectives of metrology, Categories of metrology,
Scientific metrology, Industrial metrology, Legal metrology, Need of
inspection, Revision of --Precision, Accuracy, Sensitivity, Readability,
Calibration, Traceability, Reproducibility, Sources of errors, Factors
affecting accuracy, Selection of instrument, Precautions while using an
instruments for getting higher precision and accuracy. Concept of least
count of measuring instruments (No questions to be set on revision).

1.2Standards and Comparators -------------------12Marks
Definition and introduction to line standard end standard, Wavelength
standard and their comparison, Slip gauge and its accessories.
Definition, Requirement of good comparator, Classification, use of
comparators, Working principle of comparators, Dial indicator, Sigma
comparator, Pneumatic comparator- high pressure differential type,
Electrical ( LVDT), Relative advantages and disadvantages.











09



















18









2 Limits, Fits ,Tolerances and Gauges ----------------08Marks
Specific Objectives
To understand the basics of limits, fits & tolerances
To calculate the basic and gauge tolerances.
To understand various types of gauges and their applicability.

2.1 Concept of Limits, Fits, And Tolerances, Selective Assembly,
Interchangeability, Hole And Shaft Basis System, Taylors Principle,
Design of Plug, Ring Gauges, IS919-1993 (Limits, Fits & Tolerances,
Gauges IS 3477-1973), Study of relation gauges, concept of multi gauging
and inspection.







06




08
4

3 Angular Measurement ----------------------08Marks
Specific Objectives
To understand the basics of angular measurement and measure
angles using different instruments.
3.1Concept, Instruments For Angular, Measurements, Working And Use of
Universal Bevel Protractor, Sine Bar, Spirit Level, Principle of Working of
Clinometers, Angle Gauges (With Numerical on Setting of Angle
Gauges).Angle dekkor as an angular comparator.





04



8
4.Threads and Gear Metrology --------------------------------16Marks
Specific Objectives
To Understand & use various methods of calculating thread
elements and elements of gear tooth
4.1Screw thread Measurements 08Marks
ISO grade and fits of thread, Errors in threads, Pitch errors, Measurement
of different elements such as major diameter, minor diameter, effective
diameter, pitch for internal and external threads , Three wire method,
Thread gauge, screw thread micrometer, Working principle of floating
carriage micrometer.
4.2 Gear Measurement & Testing 08Marks
Analytical and functional inspection, Measurement of tooth thickness by
constant chord method, base tangent method, gear tooth vernier, Errors in
gears such as backlash, run out, composite, concentricity. Parkinson gear
tester.













06











16
5.Testing Techniques ---------------------------------10Marks
Specific Objectives:
To know terminology of surface finish & measure the surface finish
of various components.
5.1Measurement of surface finish --------------------06Marks
Primary and secondary texture, Sampling length, Lay, terminology as per IS
3073- 1967, direction of lay, Sources of lay and its significance, CLA, Ra,
RMS values and their interpretation, Symbol for designating surface finish
on drawing, Various techniques of qualitative analysis
5.2Machine tool testing --------------------------04Marks
Parallelism, Straightness, Squareness, Coaxiallity, roundness, run out,








06









10
5








alignment testing of machine tools such as lathe, milling machine and
drilling machine as per IS standard procedure. Study of optical flat for
flatness testing.



6.Quality Control ---------------------------12Marks
Specific Objectives:
To understand the concept of Quality, cost of quality.
To understand the concept and principles of TQM.

6.1 Quality : ---------------------------06Marks
Definitions, meaning of quality of produce& services, Quality
characteristics, Quality of design, Quality of conformance, Quality
of performance, Concept of reliability, Cost, Quantity assurance,
Cost of rework & repair, Quality & Inspection, Inspection stages.
6.2 Total Quality Management : ----------------06Marks
Principles and concept of total quantity management.
a) Quality Audit: Concept of audit practices, lead assessor certification.
b) Six sigma: Statistical meaning, methodology of system Improvement.
c) Introduction of ISO 9001-2008.ISO-14000 and TS 16949.












07







12
7 Statistical Quality Control -----------------28Marks
Specific Objectives:
to know the basics of statistics.
To understand different data types and analyze & interpret the data

7.1 Statistical Quality Control --------------------20Marks
Basics of Statistical concepts, Meaning and importance of SQC, Variable
and attribute Measurement. control charts inherent and assignable sources
of variation, control charts for variables X & R charts, control charts for
attributes p, np, C charts, process capability of machine, , C
p
and C
pk

calculations, determination of statistical limits, different possibilities,
Rejection area, Statistically capable and incapable processes (20 marks)
7.2Acceptance Sampling --------08Marks
Concept, Comparison with 100% inspection, Different types of sampling
plans, sampling methods, merits and demerits of acceptance sampling. OC
Curve.
( 08 marks)



10



28
Total 48 100
6

PRACTICALS:
Skills to be developed:
Intellectual skills:
1 To select basic measuring instruments.
2 To calculate least count of various measuring instruments.
3. To collect, record and analyze the data.
4. To interpret the results of data analysis.
Motor skills:
1. Measure the dimensions of component using various instruments.
2. To take care of instruments.
3. To draw various charts and curves related to data.
4. To handle various instruments.





List of Practical:

1. Measurement of various dimensions& dimensional parameters using
instruments such as radius gauge, pitch screw gauge, filler gauge, vernier
caliper, vernier height gauge, vernier depth gauge, dial type vernier caliper,
micrometer, inside micrometer, tube micrometer.
Note: -1) The student should measure at least 3 dimensions of given job and
take 5 readings per dimension.
2) Individual performing the measurement with one setup on one
surface plate and simultaneous 4 to 5 setup should be kept ready for
measurement.( At least 10 Vernier calipers, Micrometers with
different range i.e. 0-25mm two nos. , 25- 50 two nos. Inside
micrometer, tube micrometer, V anvil micrometer at least one.)

2. To set the Adjustable snap gauge GO end and NOGO end for a given
dimensions using slip gauges.

3. Inspection of given components using Dial Indicator as a mechanical
comparator.
4. To check the given component using high pressure Dial type pneumatic
comparator.

5. To find unknown angle of component using bevel protractor and verify the
same using sine bar/ sine center and slip gauges.
6. To measure the angle of component with the Angle Dekkor/Autocollimator
using angle gauge.

7. Measurement of screw thread elements by using screw thread micrometer,
screw pitch gauge & their verification with the help of profile projector/tool
7

Batch size of students for experiment 2 to 13 shall be 4 to 5.
4 to 5 experimental setups should be arranged simultaneously.

Assignment:
1. Visit the industries to collect the data for p and c chart, study the coordinate
measuring machine and study the quality management systems.
2. Selection of comparators for the given dimensional data


Learning Resources:
Sr.No. Author Title Of Book Edition Publisher
01
R. K. Jain
Engineering
metrology
2010 Khanna Publisher, Delhi.
02 M. Mahajan Text book of
metrology
Second
Reprint-
2010
Dhanpat Rai & Co.
03
I.C. Gupta
A text book of
Engineering
metrology
Dhanpat Rai and Sons
04 M. Mahajan Statistical Quality
Control
2010 Dhanpat Rai and Sons
05 Douglas C.
Montgomery
Statistical Quality
Control
Sixth
reprint
2011
Wiley India Pvt. Ltd.
makers microscope.

8. Measurement of gear tooth elements by using gear tooth vernier caliper and
verification of gear tooth profile using profile projector.
9. To measure surface roughness using surface roughness measuring instrument.
Measure surface roughness of turning, milling ,shaping ,grinding and lapping
surfaces.

10. Testing of lathe machine/drill machine for parallelism, squareness, trueness by
Test Dial indicator.

11. Draw the frequency histogram, frequency polygon for given samples (min 50
readings) and find mean, mode, median.
12. To draw the normal distribution curve and find standard deviation, variance,
range and determine process capability.

13. To draw and interpret the control Charts (X bar and R chart, P chart, C
chart) for given data.
8

06 Dale H.
Besterfield
and others
Total Quality
Management
Third
Reprint
2012
Pearson


2. IS/ International Codes:
IS 919 1993 Recommendation for limits, fits and tolerances
IS 2029 1962 Dial gauges.
IS 2103 1972 Engineering Square
IS 2909 1964 Guide for selection of fits.
IS 2921 1964 Vernier height gauges
IS 2949 1964 V Block.
IS 2984 1966 Slip gauges.
IS 3139 1966 Dimensions for screw threads.
IS 3179 1965 Feeler gauges.
IS 3455 1966 Tolerances for plain limit gauges.
IS 3477 1973 Snap gauges.
IS 6137 1971 Plain plug gauges.
IS 3651 1976 Vernier Caliper
IS 4218 - Isometric screw threads
IS 4440 1967 Slip gauges accessories
IS 5359 1969 Sine bars
IS 5402 1970 Principle and applications of sine bars